Marine Nitrogen Generators

– enabling intelligent tank venting

Introduction

Pres-Vac Marine Nitrogen Generators are a product of Pres-Vac Engi-

neering ApS, which has more than 60 years' experience in tank venting
systems. The marine nitrogen generators are the latest products in our
range of advanced tank venting solutions.

Pres-Vac Marine Nitrogen Generators provide systems for the marine- and
off-shore industry, which demands clean, dry nitrogen of high purity for
inerting, blanketing and purging.

Using Pres-Vac Marine Nitrogen Generators results in a cost reduction of

30-70% compared to conventional nitrogen generators. Safety, reliability,
simple installation and a small footprint characterise our systems.

Contents

PSA technology 3

Overall design 6

Main features 8

Benefits 10

Specifications 12

Applications 13

Safety and compliance 14

Service and maintenance 15

2
PSA technology

CARBON MOLECULAR SIEVE - CMS

Pressure swing adsorption (PSA) and membrane gas separation
are the two most common technologies available when producing
on-site nitrogen. Flue gas systems can also be used for inerting
cargo tanks. However, due to the high level of impurities in flue
gas, the use of these systems is limited to crude oil cargoes
and can be excluded when transporting clean cargoes, that are
vulnerable to contamination.
Traditionally, most nitrogen generators have been based on mem-
brane technology, but PSA technology has proven to be superior,
offering numerous operational advantages and greater cost
efficiency. Today, PSA technology is regarded as the technology of
the future, when it comes to the on-site production of nitrogen.
In existence for over 100 years, PSA technology is used exten-
sively for various on-shore applications. Compared to convention-
al membrane technology, PSA technology is significantly simpler
and much more energy efficient, resulting in large savings on
overall operational costs.
The base material used in the PSA process is carbon molecular
sieve (CMS), which is a non-toxic, non-flammable carbon-based
material processed into a porous material using various additives.
A stable, passive material, CMS is not consumed and does not
wear down or deteriorate when producing nitrogen.
At ambient air pressure, CMS does not react to air. When exposed
to 6-10 bars of pressurized air, however, CMS starts adsorbing
(capturing) oxygen molecules and allows nitrogen to pass.
When pressure is reduced, the adsorption process stops and the
oxygen molecules are released from the porous surface of the
CMS.
The efficiency of CMS in the Pres-Vac Marine Nitrogen Genera-
tor remains constant over the entire system life cycle. The CMS
material has a designed lifetime of more than 40,000 operation
hours.

CMS CHARACTERISTICS

No deteriorations
Non-flammable
Non-toxic
Lifetime of more than 40,000 operation hours
Pellet size: 2-5 mm

3
PSA technology

PRESSURE SWING ADSORPTION (PSA)

A PSA system requires a minimum of two identical pressure ves- This alternating process is referred to as pressure swing adsorp-
sels filled with CMS. One pressure vessel is always in nitrogen tion.
producing mode, while the other is in recovery mode. After about A sequence controlled valve system distributes compressed air
one minute, the pressure between the two vessels is equalised. into the pressure vessel, as described below.
Subsequently, the modes swing and when the vessel is in recov-
ery mode, it enters production mode and the pressure vessel in
production mode enters recovery mode.

N2 outlet

A1 A2

1 2
Exhaust outlet
C1
C2

D1
D2

Air inlet

PSA production mode – pressure vessel 1
Exhaust valve C1 is closed and Outlet valve A1 and Inlet valve
D1 open.
Compressed air starts to flow through the pressure vessel 1.
Oxygen is captured by the CMS and the nitrogen leaves the
pressure vessel through N2 outlet.
After approximately one minute the production mode stops
and Outlet valve A1 and Inlet valve D1 close.
PSA recovery mode – pressure vessel 2
Outlet valve A2 and Inlet valve D2 are closed and Exhaust
valve C2 opens.
A small flow of nitrogen from tank 1 is purged into the top of
tank 2, flushing the oxygen adsorbed by the CMS out of the
tank via Exhaust outlet.

4
PRESSURE SWING ADSORPTION (PSA)

N2

CMS

O2
N2

O2 N2

Exhaust Exhaust
outlet outlet

Compressed air

5
Overall design
FLEXIBLE DESIGN NITROGEN PROCESS MODULE

Pres-Vac Marine Nitrogen Generators are delivered as complete
system packages using a standard hardware platform. The
system comprises two main modules:
Air supply module
Nitrogen process module
Delivered pretested and ready to use with few external con-
nections and minimised cabling, the modules can be installed
quickly and easily.
The main components in the nitrogen process module are:
PSA adsorption modules, control system, oxygen analyser, flow
regulators and control valves. The nitrogen process module is
standard skid mounted and both coal tower and pre-micron
filter are also mounted on the skid for customer convenience.
The PSA units can also be delivered as split units. This will ena-
ble individual location of the components in the nitrogen supply
module and thereby safe installation space – making Pres-Vac
Marine Nitrogen Generators ideal for retrofitting.  

Filters Remove particles from

PSA Porous CMS material adsorbs compressed air
oxygen molecules

N2 outlet High purity nitrogen flows N2 outlet High purity nitrogen flows Dry air outlet from 0-10 bars
from PSA 0-10 bars from PSA 0.13-0.17 bars

6
 AIR SUPPLY MODULE

Main components in the air supply module: Compressors and air dryers are delivered as stand-alone units,
Compressors which can be installed at individual locations.
Air dryers
Coal tower Compressors and air dryers are advanced systems. Developing
Pre-micron filters and producing them is thus limited to a number of highly special-
ised international companies.
The coal tower and the filters are physically
located on the PSA unit. Because Pres-Vac is not associated with any specific manufac-
turer, we are able to meet the preferences of our customers and
thus deliver air packages from all major manufactures.

Compressor Increases air pressure

to required level from 4-12 bars
Air inlet pressure From 4-12 bars

Air dryer Removes moisture from air by

condensation of the compressed air

Coal tower Absorbs fractional impurities

and oil particles from the inlet air

7
Main features

Ideal for retrofitting

The PSA unit can be delivered as split components, which
enables individual placement and utilises limited space
optimally.

Compact design and simple installation

Modest footprint.
Easy integration – few external connections.
Minimised cabling provides quick and easy installation.
No receival- or buffer tanks required.
Modular system components.

High performance
Low power consumption due to effective system utilisation.
Reduced investments in onboard generator capacity.
Avoidance of critical overload and blackouts.
Optimised off-loading conditions shorten discharge time

A limited number of physical inter

installation 14 different standard s
Capacity range: 75-10,000 Nm3/h
N2 purity range from 95-99.999%
Voltage 3 x 380/440V, 50/60 Hz
Flow control of outlet flow and pre

8
 Wear and tear
System efficiency remains constant over entire life cycle
CMS material does not deteriorate – no replacement or up-
grades required
Few components mean less mechanical wear
Dry air means no interior corrosion

Operation
Easy and intuitive touch screen operator interface.
Fully automatic control system offering various operational
modes
Modbus communication enables easy integration with cargo-,
alarm- and control systems
Remote condition monitoring and optimisation via built-in
modem

Advanced hardware
Dry air supplied to e.g. ballast tanks
Low noise exhaust silencer below 82 dB(A)
Alarm monitoring of filters for increased safety
Angle seated valves for more precise PSA sequence control

rface points means quick and easy

systems
h
%

essure.

9
Benefits

+ Lower investment costs and safer operation

Nitrogen generators normally operate with other heavy
energy consumers (e.g. engine, cargo and ballast pumps).
Consequently, allocating sufficient electric power without
compromising the limits of the vessel’s generator system is
often a challenge. The significantly lower power consump-
tion of Pres-Vac Marine Nitrogen Generators compared to
conventional membrane systems means the size of the
switchboard and generators can be considerably reduced in
most cases.
For example, the power consumption of a Pres-Vac 4,500
Nm3/hour@95 nitrogen generator is 1,030 kW. A conven-
tional membrane-based nitrogen generator with the same
capacity has a power consumption of 1,460 kW.
Consequently, using a Pres-Vac system reduces a vessel’s
power demand by 430 kW.
+ Lower operational costs (OPEX)
A Pres-Vac Marine Nitrogen Generator consumes as little as
0.23 kW per produced m3 nitrogen at a purity of 95%.
Conventional membrane systems consume 42% more
energy at same purity.
At a purity of 99.9%, the power consumption of a conven-
tional membrane system is up to 85% higher compared to a
Pres-Vac Marine Nitrogen Generator system.
For example, operating a Pres-Vac 4,500 Nm3/hour@95%
nitrogen generator 1,500 hours a year can result in savings
of approximately 705,000 kWh per year.
Assuming that the on board production cost of a kWh is
0.25 USD/kWh, OPEX can be reduced by 160,000 USD/year.

One more substantial advantage is that a lighter load on

the switchboard and generators reduces the likelihood of
overloading and blackouts.

A reduced power demand means smaller generators. In the

above example, the generator power costs are roughly
500 USD/kW. The capital expenditure savings could be
approximately 220,000 USD.

10
10
+ Lower maintenance costs
CMS is a passive substance and does not degrade or dete-
PSA vs. membrane
– difference i power consumption
riorate when producing nitrogen. The efficiency of the CMS kW/m3 N2
in the Pres-Vac Marine Nitrogen Generator remains constant 2.0
over the entire system life cycle. The CMS does not need to PSA
be replaced or upgraded. Membrane
1.5
Maintenance is limited to daily inspections and yearly
replacement of filter cartridges. Depending on the manufac-
turer, compressors normally require service at 3,000-hour 1.0
intervals.

In conventional membrane-based systems, the vulnerability 0.5

of the membranes makes them consumables. Mechanical
and biological contamination gradually reduces their effi- Membrane
ciency. Consequently, the capacity of a membrane system N/A
0.0
slowly decreases, resulting in the need for its replacement 95 99 99.9 99.998 Purity
N2%
every five to seven years.

Less efficient membranes entail an increase in operational

costs as more energy is required to maintain a constant System capacity at different purities
5.000
capacity. The estimated cost of replacing membranes is Capacity m3/h N2
about 35% of the system’s total cost upon installation. Any 4.500
4,500
off-hiring during retrofitting of membranes could also gener- 4.000 PSA
ate loss in vessel earnings. Membrane
3.500
3,375
3.000
2.500
2,250 Series1
2.000
1.500
1,125
1.000
500 Membrane
00 N/A

1 95 2 3 99 4 5 99.9 6 799.998 Purity

N2%

11
Specifications

STANDARD SYSTEM RANGE

Model Standard Capacity Number of compressors Number of dryers Number of PSA units

PV 10 75 Nm3/hour@95%
PV 20 110 Nm3/hour@95%
PV 30 160 Nm3/hour@95%
PV 40 280 Nm3/hour@95%
PV 50 450 Nm3/hour@95%
PV 60 600 Nm3/hour@95%
PV 70 900 Nm3/hour@95%
PV 80 1,250 Nm3/hour@95%
PV 90 1,800 Nm3/hour@95%
PV 100 2,300 Nm3/hour@95%
PV 110 3,500 Nm3/hour@95%
PV 120 4,500 Nm3/hour@95%
PV 130 5,800 Nm3/hour@95%
PV 140 7,000 Nm3/hour@95%

Air supply module Nitrogen process module

Non hazardous area Non hazardous area

PSA adsorption vessels Oxygen analyser Nitrogen flow

regulator

Air Pre-micron
compressors filters

Post-
micron
filter
Carbon
tower

Air dryer
Deck storage
vessel (optional)

Power supply Dry air outlet Hazardous Double block

Fresh water cooling (optional) area and bleed
Air inlet (optional)

N2 outlet

12
Applications

OIL AND PRODUCT TANKERS

Inerting cargo tanks during discharge

Blanketing cargo tanks
Purging pipelines

LEG, LPG & LNG CARRIERS

Inerting cargo tanks during discharge

and tank repair
Blanketing cargo tanks
Purging pipelines

DRILLING AND OFF-SHORE

Inerting cargo tanks during discharge

Blanketing
Purging pipelines
BOP supply

SUPPLY VESSEL

Blanketing tanks during discharge

Purging
Purging drill mud

GENERAL PURPOSE

Blanketing tanks during discharge

Purging
Purging drill mud

13
Safety and Compliance
REGULATORY COMPLIANCE
Pres-Vac Nitrogen Generators comply with all relevant standards.
Our goal is to be best in class .
IMO COMPLIANCE
Pres -Vac Nitrogen Generators comply with the IMO International
Convention for the Safety of Life at Sea (SOLAS).
CLASS COMPLIANCE
Pres-Vac Nitrogen Generators complies with rules from major
classification societies.
MED MARK OF CONFORMITY - “WHEELMARK”
Marine equipment can only be installed onboard ships flying
the flag of an EU country, Norway or Iceland (EFTA countries),
or other flag states if marked with the MED Mark of Conformity.
Pres-Vac Marine Nitrogen Generators comply with the most
recent amendment of MED 96/98/EC. Pres-Vac Marine Nitrogen
Generators are listed in the MarED Product Database.
Safety. Compliance. Performance.
Safety and regulatory compliance go hand in hand. Based on a firm under-
standing of the rules and requirements, Pres-Vac products are developed to
pass approval processes and to operate for many years.
14
NOISE COMPLIANCE
Pres-Vac Marine Nitrogen Generators comply with the Code on
Noise Levels on Board Ships.
DESIGN AND MANUFACTURING
All of our models incorporate the requirements of leading agen-
cies. Every order undergoes a design assessment by a selected
agency. Pres-Vac Marine Nitrogen Generators are designed and
manufactured according to PED (97/23/EC), ISO 9001 (Quality)
and ISO 14001 (Environmental), certified by Apragaz
FACTORY ACCEPTANCE TEST - FAT
FAT inspections ensure that the system is built according to
pre-approved design documents and cover testing, scope, sup-
ply, manufacturing processes, functionality and performance.
When the FAT report is approved, the system is shipped to the
yard for installation and commissioning.
COMMISSIONING
Commissioning, which is conducted in the yard, ensures that the
system is installed and lives up to the FAT.
Participation in Sea Acceptance Test (SAT) is optional.
Service and Maintenance
NETWORK OF SERVICE REPAIR CENTRES
Active in the marine market since 1952, Pres-Vac has estab-
lished an extensive worldwide network that also includes various
international service and repair centres in strategic marine hubs.
The technical skills and marine experience these centres have in
repairing Pres-Vac equipment allow us to provide a high level of
service for all our customers.
Conveniently located around the world, our Service Repair
Centres permit rapid access to spare parts and qualified service
repair engineers.
The number of Service Repair Centres is steadily growing and
new locations will appear in the near futu.
Service and Repair Centre skills
Our service engineers have been trained and certified to overhaul
Pres-Vac products according to our specifications. Our engineers
carry individual Pres-Vac ID cards, so you know you are getting
the service you trust and expect.
Dynamic Performance and Monitoring System
Pres-Vac is currently developing a dynamic maintenance and per-
formance system (DMPS). A built-in modem enables both users
and Pres-Vac to retrieve system process and performance data.
System data are retrieved and analysed on a regular basis, while
the system performance is compared to previously recorded data
to determine whether the system should be adjusted.
This approach will ensure that the nitrogen system remains 100%
operative and that it will constantly deliver the best performance
possible. Performance data are also used for preventive main-
tenance, enabling online adjustments and live advice in order to
avoid failures or malfunctions in a timely manner.

Pres-Vac locations

Certified Pres-Vac Service Centers SRC

Upcoming Service Centers

Pres-Vac Service Repair Centres Pres-Vac locations

15
 About Pres-Vac Engineering ApS

For more than 60 years, Pres-Vac Engineering

has been supplying pressure/vacuum valves
and venting equipment to the tanker shipping
industry.

Today, we are the worlds’ leading supplier of

intelligent tank venting and roughly 50% of
all tanker vessels world-wide use Pres-Vac
equipment.

We work with shipyards, naval architects and

other partners on all continents. We have a
network of highly professional, experienced
agents and distributors in all major ship own-
ing and ship building countries.

Pres-Vac Engineering ApS

Svanevang 3-5
DK-3450 Allerød
Denmark

Tel. +45 48 17 40 55
Fax +45 48 17 17 88
Email presvac@pres-vac.com
Website www.pres-vac.com
This catalogue is subject to change and / or printing errors.
002/li Oktober 2014

nitrogen